Three-way mounting of an air conditioner

ABSTRACT

An evaporator unit for an air conditioning system includes a housing having a back panel and a front section. The front section defines an air inlet at one end and an air outlet at an opposite end thereof. The housing defines an air flow path through the unit extending from the inlet to the outlet. An evaporator coil is supported in the housing in the air flow path. The unit includes an evaporator fan for effecting air flow along the air flow path and through the evaporator coil where the air is cooled and water is removed therefrom resulting in condensation. The unit includes a first condensate collection pan mounted in the housing adjacent to the evaporator coil. The first condensate collection pan is configured to collect condensate from the evaporator coil when the evaporator unit is mounted with the back panel in a substantially vertical orientation with one end defining the lower end of the housing and the opposite end defining the upper end of the housing. The first condensate collection pan is further configured to collect condensate from the evaporator coil when the evaporator unit is mounted with the back panel facing upwardly in a substantially horizontal orientation. The unit includes a second condensate collection pan within the housing, which is configured to collect condensate from the evaporator coil when the unit is mounted with the back panel in a substantially vertical orientation with the air inlet at the upper end of the housing and the air outlet at the lower end of the housing.

TECHNICAL FIELD

The invention generally relates to air distribution units of the typecommonly used in air conditioning, heating or ventilation systems and,more particularly, to such a unit which may be mounted in severaldifferent orientations.

BACKGROUND ART

In many commercial air conditioning, heating and ventilating systems,treated air is discharged into an area to be conditioned through an airdistribution or conditioning unit. For example, one general type of airconditioning system, often referred to as a split system, includesseparate indoor and outdoor units. The outdoor unit includes acompressor, a heat exchanger and a fan. The indoor unit includes a heatexchanger and a fan. In operation, the indoor fan draws air into theindoor unit, through an inlet thereof, and forces the air over theindoor heat exchanger and then out of the indoor unit, through an outletopening therein.

The outdoor fan draws air into the outdoor unit, through an inlet,forces that air over the outdoor heat exchanger and then forces that airout of the outdoor unit through an outlet therein. At the same time, acompressor causes a refrigeration fluid to circulate through and betweenthe indoor/outdoor heat exchangers. At the indoor heat exchanger, therefrigerant absorbs heat from the air passing over that heat exchanger,cooling that air. At the same time, at the outdoor heat exchanger, theair passing over the heat exchanger absorbs heat from the refrigerantpassing therethrough. Typically a louvered assembly is disposed in theoutlet of the indoor unit to direct the air discharge from that unit ata preferred angle.

Commonly, the indoor unit of a split system is mounted on the floor of aroom against a wall thereof. In some situations, however, it isdesirable to place the indoor unit in other locations, such as on theceiling of the room or on the wall at a position above the floor. Whenmounting the indoor unit on the wall above the floor, a mounting whichis commonly referred to as a “hi-wall split mount”, it is desirable forthe air discharge to be located at the bottom of the unit. Accordingly,a unit would be oriented exactly opposite from the mounting of a consolemount unit.

A further benefit to the conditioning of the indoor air which occurswith such an air conditioning unit is the removal of undesired humidityin the air as the air being cooled is passed by the indoor heatexchanger. This dehumidification results in an accumulation of water ashumidity condenses on the cold indoor heat exchanger coils. It isaccordingly necessary to collect the removed water and divert it to anappropriate disposal point.

It should be appreciated that an indoor unit of an air conditioner,which may be mounted in each of the above-mentioned floor mount, ceilingmount, and hi-wall mount, with a bottom discharge orientation, whilestill providing the ability to collect the condensate from the unitwould be extremely desirable.

An indoor unit for an air conditioning system which may be mounted as afloor, ceiling and wall mount is shown and described in U.S. Pat. No.5,044,260. The air distribution unit, however, of the '260 patentprovides a wall mount orientation with the air discharge at the top ofthe unit, which compromises the ability to place the unit in the highwall location, which is desirable of such units. Because the '260 unitmust be mounted in the hi-wall application in the same orientation asthe floor mount, in order to collect condensate, the unit must bemounted substantially below the ceiling line in order to achieveacceptable air discharge flow from the top of the unit.

DISCLOSURE OF THE INVENTION

An evaporator unit for an air conditioning system includes a housinghaving a back panel and a front section. The front section defines anair inlet at one end and an air outlet at an opposite end thereof. Thehousing defines an air flow path through the unit extending from theinlet to the outlet. An evaporator coil is supported in the housing inthe air flow path. The unit includes an evaporator fan for effecting airflow along the air flow path and through the evaporator coil where theair is cooled and water is removed therefrom resulting in condensation.The unit includes a first condensate collection pan mounted in thehousing adjacent to the evaporator coil. The first condensate collectionpan is configured to collect condensate from the evaporator coil whenthe evaporator unit is mounted with the back panel in a substantiallyvertical orientation with one end defining the lower end of the housingand the opposite end defining the upper end of the housing. The firstcondensate collection pan is further configured to collect condensatefrom the evaporator coil when the evaporator unit is mounted with theback panel facing upwardly in a substantially horizontal orientation.The unit includes a second condensate collection pan within the housing,which is configured to collect condensate from the evaporator coil whenthe unit is mounted with the back panel in a substantially verticalorientation with the air inlet at the upper end of the housing and theair outlet at the lower end of the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be better understood and its objects and advantageswill become apparent to those skilled in the art by reference to theaccompanying drawings, in which:

FIG. 1 is a perspective view of the indoor unit of an air conditionerwhich embodies the features of the present invention;

FIG. 2 is a side view of the air conditioning unit of FIG. 1 mounted ona ceiling with a portion of the outer housing broken away;

FIG. 3 is a side view of the air conditioning unit of FIG. 1 mounted ona vertical wall adjacent to the ceiling with a portion of the outerhousing broken away;

FIG. 4 is a view of the air conditioning unit of FIG. 1 mounted on afloor in a console mount with a portion of the outer housing of the unitbroken away;

FIG. 5 is an exploded perspective view of the air conditioning unit ofFIG. 1;

FIG. 6 is a perspective view of the air conditioning unit of FIG. 1 withthe outer housing and some of the internal components thereof removed;

FIG. 7 is a vertical sectional view taken along the line 7—7 of FIG. 6;and

FIG. 8 is a vertical sectional view taken along the line 8—8 of FIG. 6.

BEST MODE FOR CARRYING OUT THE INVENTION AND INDUSTRIAL APPLICABILITY

The drawing figures illustrate an indoor unit 10 of a split system airconditioner. As will be seen as the description continues, the unitincludes an outer housing 12, evaporator fans 14, evaporator heatexchanger 16, and upper and lower condensate collection pans 18 and 20,respectively. Generally, the housing 12 defines an interior space formounting the other components and defines an air flow path through theunit from an inlet 22 for conducting air into the interior and an outlet24 for discharging air from the interior of the housing into the spaceto be conditioned. The fans 14, heat exchanger 16 and upper and lowercondensate pans 18 and 20 are secured within the housing 12. An inletgrill 26 forms part of the housing and is located over the air inlet 22and a discharge louver assembly 28 is located in the outlet 24.

In operation, a heated or chilled fluid is circulated through theevaporator heat exchanger 16. At the same time the fans 14 draw air intothe housing 12 form the space to be conditioned, and force that air overthe heat exchanger 16 thereby heating or cooling the air, and forcingthe conditioned air through the outlet 24 and back into the space beingconditioned. The upper and lower condensate pans 18 and 20 are alsosupported within the housing 12 adjacent the upper and lower endsrespectively of the heat exchanger to collect water that condenses onand drips downward from the heat exchanger during operation of thesystem. As a result of the configuration of the upper and lowercondensate pans 18 and 20, the air conditioner unit 10 may be operatedin a console mount position, as illustrated in FIG. 4, a ceiling mountposition, as illustrated in FIG. 2 or in a high-wall mount with the airdischarge 24 at the lower end thereof, as illustrated in FIG. 3. As aresult of the unique configuration of the upper and lower condensatepans, the unit may be operated in any of these orientations while stillcollecting and disposing of water that condenses on and drips downwardfrom the heat exchanger 16.

Looking now at FIGS. 5, 6 and 7, the housing 12 includes a one-piecestructural sheet metal frame 30, which defines the back panel 32, thebottom 34 and an upper flange 36. Structurally attached to opposite endsof the sheet metal structure 30 are internal side panels 38. Each of theside panels 38 is provided with a horizontally extending slot 40, whichextends from front to back and a triangular shaped section 42, whichextends upwardly from the slots 40 and which each define an angularlypositioned heat exchanger mounting surface 44.

A horizontal sheet metal fan mounting panel 46 is adapted to be receivedin the horizontal slots 40 of the internal side panels 38, as shown inFIG. 5. The fan mounting panel 46 separates the interior of the housinginto the lower inlet section 48, which communicates with the previouslydescribed inlet 22 via the inlet grill 26 and the outlet section 50above the fan panel in which the heat exchanger coil 16 is mounted onthe inclined surfaces 44 of the internal side panels 38, as bestillustrated in FIG. 7.

Referring back to FIG. 5, the evaporator fan 14 comprises an electricmotor 52 mounted to the underside of the fan mounting panel 46, which isadapted to drive a pair of centrifugal fans 54 which are in turnenclosed in a two-piece scroll assembly 58, each of which are attachedto the lower side of the fan mounting panel 46 and which communicatewith rectangular discharge openings 62 in the fan panel.

As best seen in FIGS. 5, 6 and 7, the upper condensate pan 18 comprisesa one-piece elongated section fabricated from a foamed plastic material.The pan comprises a central section 56 having a top face 60 adapted tobe received and retained under the upper flange 36 of the one-piecesheet metal structural frame 30. The central section 56 also has a backface 70 and a downwardly extending section 72, the back face 70 beingadapted to be in confronting relation with the back panel 32 of thesheet metal section 30 and the lower section adapted to be receivedbehind the upper end of the triangular section 42 of the internal sidepanels 38. As so retained, the upper condensate pan 18 has asubstantially planar heat exchanger support surface 74, which is at anangle so as to be in confronting supportive relationship with the top ofthe heat exchanger 16, as defined by the upper ends of the tube sheets76 and the heat exchanger fins 78.

As best seen in FIGS. 7 and 8, the upper condensate pan 18 includes alongitudinally extending condensate collection channel 80 passing fromthe planar section 74 and internally into the collection pan at arearwardly extending orientation.

The left and right-hand ends of the upper condensate pan 18 includeextensions 82 from the central section 56, which are configured tooverlie the return bends 81 of the heat exchanger coil extending to theleft and right of the tube sheets and forming a condensate collectionrecess 79 therein, which is in fluid communication with the condensatechannel 80.

With reference to FIGS. 5, 6 and 7, the lower condensate pan 20 is aone-piece component fabricated from plastic foam. The pan includes asubstantially planar front section 64, left and right lateral extensions66, and a lower heat exchanger support section 68. The condensate pan 20is adapted to be installed to the unit following installation of theupper condensate pan 18 and the evaporator heat exchanger 16.

As best seen in FIGS. 7 and 8, the lower heat exchanger support section68 has a substantially triangular cross-section having a lower surface84 engaging the upper surface of the front of the fan mounting panel 46and an inclined longitudinally extending surface 86 adapted to supportthe lower ends of the heat exchanger tube sheets 88 and the lower endsof the heat exchanger fins 90. A flat longitudinally extending righthand facing surface 92 abuts against a forwardly facing surface of eachof the internal side panels 38. Further, an upwardly extending lip 94 isformed on the front side of the fan mounting panel 46, which serves toengage a lower portion 96 of the planar front section 64 of the lowercondensate pan to assist in positioning and retaining the pan in thedescribed position.

With reference to FIG. 6, it will be noted that the planar front section64 of the lower condensate pan is supported in a substantially verticalorientation spaced from the heat exchanger coil with the upper end 98thereof spaced from the front edge 100 of the upper condensate pan 18.The opening defined by the edges 98 and 100 defines part of the air flowdischarge path through the unit. With reference to FIGS. 5-8, the uppercondensate pan 20 is supported in the above-described spacedrelationship from the heat exchanger coil by a center spacer 102extending from the top edge 98 of the condensate pan and adapted toengage the front of the heat exchanger coil at the top thereof underlingthe front edge 100 of the upper condensate pan. As best shown in FIGS.6, 7 and 8, additional support spacing of the lower condensate pan 20 isprovided by lateral walls 106 on the left and right-hand sides of theplanar front section 64, which are adapted to engage the front surface108 of the heat exchanger tube sheets to thereby not only position thelower condensate pan, but provide an air tight seal therebetween tofurther define the above-described air flow path.

As best seen in FIGS. 1 and 5, an outer cover 100, which includes theinlet grill 26, a solid section 112 and an elongated opening 114 inwhich the discharge louvers 28 are mounted, is adapted to bestructurally attached to and cover the front and the top of indoor unit10. External side covers 18 and 120 are adapted to be attached to theleft and right sides of the unit to complete the outer housing, asillustrated in FIG. 1.

The indoor evaporator unit 10, as described above, is capable of beinginstalled in the three different orientations illustrated in FIGS. 2, 3and 4. In FIG. 4, a console installation is shown wherein the unit ismounted with the bottom 34 on a floor and the back panel 32 against aninterior wall. The inlet/inlet grill 22/26 are located at the bottom ofthe unit and the air discharge/discharge louver 24/28 is located at theupper side to thereby direct the air from the upper end into the room.As illustrated in FIG. 6, the fins of the heat exchanger 16 extendvertically with the heat exchanger tubes extending transversely. Withthis configuration, any condensate removed from the air passing throughthe heat exchanger will fall under the influence of gravity downwardlyfollowing the fins and/or tube sheets to the angularly disposed heatexchanger mounting surface 86 of the lower condensate pan 20.

It will be noted, as shown in FIGS. 7 and 8, that an elongatedcondensate collection slot 130 extends the length of the lower heatexchanger support section 68. The collection slot 130 communicates atits right and left-hand ends with a plenum 132. as shown in FIG. 8.Either the left or right-hand plenum may be interconnected with asuitable drain tube 134 such as shown in FIGS. 6 and 8, which is adaptedto conduct collected condensate to an appropriate disposal location.

Looking, now at FIG. 2, the unit 10 is shown with the back panel 32 in ahorizontal position attached to the ceiling of a room to be conditionedand with the bottom 34 adjacent an interior wall. As such, theinlet/inlet grill 22/26 faces downwardly and the outlet/dischargelouvers 24/28 is also directed downwardly into the space to beconditioned. When oriented in this manner, condensate forming on theheat exchanger 16 will fall downwardly under the influence of gravityand be collected by the inside 140 of the planar front section 64 of thelower condensate pan 20. The collected condensate will migrate to a lowpoint 142 which communicates with the plenum 132, as illustrated in FIG.8. The plenum 132 is then appropriately interconnected with a drain tubepassing through an opening in the bottom of the side section 66 of thecondensate pan 20. The drain arrangement is similar to that shown inFIG. 8 and will not be shown in detail.

FIG. 3 illustrates the unit 10 mounted in a high-wall installationwherein the back panel 32 is adjacent to an indoor wall and the “bottom”34 is in contact with the ceiling of the room to be conditioned. As soinstalled, the air inlet/inlet grill 22/26 is located at the top of theunit adjacent the ceiling while the air outlet/discharge louver 24/28 islocated at the lower end of the unit and discharges outwardly anddownwardly into the space to be conditioned. When installed in thismanner. water which condenses on the heat exchanger 16 will flowdownwardly and to the left following the fins and/or tube sheets of theheat exchanger to the inclined support surface 74 of the uppercondensate pan 18.

As best shown in FIGS. 7 and 8, the upper condensate collection channel80 is aligned with the lower right-hand corner of the heat exchanger, asviewed in FIG. 3. The condensate collection channel 80 is adapted toreceive condensate from the heat exchanger and is in fluid communicationat the left and right-hand ends thereof with the collection recess 79,as illustrated in FIG. 8. Further, as shown in FIG. 8, an appropriatedrain tube (not shown) may be installed in fluid communication with thecollection recess 79 at either the left or right sides of the uppercondensate pan 18 to thereby direct the collected condensate to anappropriate disposal location.

What is claimed is:
 1. An evaporator unit for an air conditioningsystem, the evaporator unit being of the type which includes: a housinghaving a back panel and a front section, the front section defining anair inlet proximate one end thereof and an air outlet proximate anopposite end thereof, the housing further defining an air flow paththerethrough extending from said inlet to said outlet; an evaporatorcoil supported in said housing in said air flow path; and an evaporatorfan for effecting air flow along said air flow path and through saidevaporator coil, whereby water is removed from said air flowing throughsaid evaporator coil as a result of condensation upon the cold surfaceof the coil. wherein the improvement comprises: a first condensatecollection pan mounted in said housing proximate to said evaporatorcoil, said first condensate collection pan being configured to collectcondensate from said evaporator coil when said evaporator unit ismounted with said back panel in a substantially vertical orientationwith said one end defining the lower end of said housing, and saidopposite end defining the upper end of said housing, said firstcondensate collection pan further being configured to collect condensatefrom said evaporator coil when said evaporator unit is mounted with saidback panel facing upwardly in a substantially horizontal orientation;and a second condensate collection pan mounted in said housing proximateto said evaporator coil, said second condensate collection pan beingconfigured to collect condensate from said evaporator coil when saidevaporator unit is mounted with said back panel in a substantiallyvertical orientation with said one end defining the upper end of saidhousing, and said opposite defining the lower end of said housing. 2.The apparatus of claim 1 wherein with reference to said back panel in asubstantially vertical orientation, with said one end defining the lowerend of said housing and said opposite end defining the upper end of saidhousing, said evaporator coil is oriented in an inclined position withan upper end thereof proximate said back panel and said opposite end,and the lower end of said coil is proximate said front section of saidhousing; wherein said second condensate collection pan overlies and iscoextensive with said upper end of said evaporator coil; and whereinsaid first condensate collection pan underlies and is coextensive withsaid lower end of said evaporator coil.
 3. The apparatus of claim 2wherein said first condensate collection pan further extendssubstantially vertically upwardly parallel to said front section adistance such that the upper end of said second condensate collectionpan is spaced from said second condensate collection pan to togetherdefine a portion of said air flow path.
 4. The apparatus of claim 2wherein said evaporator coil comprises right and left-hand tube sheets,having a plurality of horizontally disposed tubes extending therebetweendefining a refrigerant flow circuit therethrough, said evaporator coilfurther comprising a plurality of heat exchange fins mounted on saidplurality of tubes and substantially perpendicular thereto, whereby theflow of water condensing on said tubes and said fins will be in thedirection of said fins.
 5. The apparatus of claim 4 wherein each of saidfirst condensate collection pan and said second condensate collectionpan extends at the left and right-hand ends thereof beyond the left andright-hand tube sheets of said evaporator coil.
 6. The apparatus ofclaim 5 wherein at least one of said tube sheets includes refrigerantinlet and outlet means communicating with said horizontally disposedtubes and wherein each of said first and second condensate pans extendlaterally outwardly of said inlet and outlet means.
 7. The apparatus ofclaim 6 wherein said first condensate collection pan comprises ahorizontally extending condensate collection slot disposed adjacent thelower most end of said evaporator coil; and wherein said secondcondensate collection pan comprises a condensate collection slot thereinadjacent the upper most section of said evaporator coil.
 8. Theapparatus of claim 7 wherein said first condensate collection panfurther includes means therein in fluid communication with said slotadapted to be accessible by condensate drain means; and wherein saidsecond condensate collection pan includes means therein in fluidcommunication with said slot adapted to be accessible by condensatedrain means.
 9. The apparatus of claim 8 wherein both of said condensatecollection pans are fabricated from a molded foam material.